EFFECTIVE KAIZEN IMPLEMENTATION

INTRODUCTION

What is an effective Kaizen?
Why is Kaizen so important for productivity improvement? 
How is Muda & Gemba related to Kaizen? 
How do we differentiate Value Adding & Non-Value Adding Activities? 
How do we increase value in our production? 

Come and explore our dynamic class with plenty of real shop floor examples and ideas of making a great effective Kaizen happen in your workplace. You will never regret it and we assure you that you will attain all precise and practical answers for the questions above.
Gemba is the place where value is created, revenue is generated and where a process and product transformation occurs. Kaizen simply means continuous improvement by eliminating waste which is muda in gemba. Kaizen is the ‘heart’ of all improvement activities and is also the first word learned by all Toyota employees during orientation. In the 1990’s gemba and kaizen has become a major jargon in global manufacturing.
However in today’s environment, many unable to see waste and differentiate between value and non-value added activities. Improvements cannot be done if we don’t get our hands “dirty”. Seeing the real place yourself is crucial to identify improvements. Understanding waste is important to increase your productivity and efficiency. By not seeing the real thing and experiencing it, we tend to implement the wrong solutions which are not suitable and waste valuable resources.
This course will be an “eye-opener” for many to solve all the problems stated above. You will learn practical ways of making your kaizen successful and effective. This course will be truly game changer to make many improvements in your workplace.

OBJECTIVES

1. Understand what is Kaizen, Gemba & Muda all about
2. Understand and implement kaizen activities
3. Able to identify wastes in gemba
4. Able to differentiate between value and non-value added activities
5. Able to understand all the tools of Kaizen such as Poka-Yoke, SMED, Jidoka & many more

DURATION

2 days-- In House – 9.00 am to 5.00 pm

WHO SHOULD ATTEND

1. Engineers, managers, supervisors, manufacturing personnel, team leaders, executives and change agents who will be involved in the shop floor
2. Anyone who wants to make improvements happen and to create value for the company

METHODOLOGY

1. Informative Presentation
2. Real Case Studies
3. Group Discussion & Presentation

Kaizen

1. Lean Principles
2. Mass Production vs Toyota Production System
3.  What is Kaizen & why is it important?
4. Objectives of Kaizen

Muda (Waste)

1. The 5G’s
2. The 3M’s
3. What is value versus non value activities?
4. The meaning of Gemba
5. Types of waste

The Tools of Kaizen

1. PDCA
2. 5S
3. Jidoka
4. 5 Why
5. Poka-Yoke
6. Takt-Time
7. Pull System
8. Quick Changeover/ SMED

Implementation of Kaizen Workshop

1. Example of a Kaizen Workshop
2. Kaizen Week
3. Kaizen Team Rules
4. Cycle Time Sheet
5. Improvement Sheet
6. Standard Working Sheet
7. Kaizen News